Coordinated Motor Circuit Protection

A Guide to Understanding: Short-Circuit Protection Devices, Overload Protection Devices, and Coordinated Protection

Table of Contents Code Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Short-Circuit Protection Devices . . . . . . . . . . . . . . . . . . 3

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Type 2 Coordination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Motor Overload Protection . . . . . . . . . . . . . . . . . . . . . . 15

Eutectic alloy overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Bimetallic alloy overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Solid-state overload relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Advanced Motor Protection . . . . . . . . . . . . . . . . . . . . . 20 Coordinated Motor Circuit Protection . . . . . . . . . . . . . . 22 Life of a Typical Motor Installation . . . . . . . . . . . . . . . . 26 Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

COORDINATED MOTOR CIRCUIT PROTECTION

CODE REQUIREMENTS
Whether you are designing motor circuits for use in North America, Europe, or any other part of the world, several basic requirement are typically specified for a motor circuit. In the U.S., the National Electrical Code (NEC) is followed as the basis for most electrical installations. In Canada, the Canadian Electrical Code (CEC) is followed, and in Europe, each country has its own electrical code requirements that must be met. Due to time and space limitations, we will address code issues in reference to the NEC unless otherwise stated. Article 430 of the NEC describes the requirements for installations involving motors, motor circuits, and controllers. In Article 430, the requirements for motor branch circuit short-circuit, and ground fault protection and motor overload protection are specified. Figure 1 identifies the control and protection components required for a motor branch circuit.
Figure 1 NEC Article 430 Motor Branch Circuit Requirements

Supply

Disconnecting Means

Short-Circuit Protection Device (SCPD)

Fuses or Circuit Breaker

Motor Controller

Motor Overload Protection

Overload Relay

Motor

Now that we have identified the components required by code to provide motor brand protection, lets take a closer look at the available types of short-circuit protection devices that will meet code requirements.
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COORDINATED MOTOR CIRCUIT PROTECTION

SHORT-CIRCUIT PROTECTION DEVICES

Short-circuit protection devices (SCPDs) can be classified into two groups; fuses and circuit breakers. The NEC further recognizes four types of fault protection devices and specifies their sizing limitations based on the type of motor that is used in the circuit. Non-time Delay Fuse Dual Element (Time Delay) Fuse Instantaneous Trip (Magnetic-only) Circuit Breaker Inverse Time (Thermal-magnetic) Circuit Breaker This review of short-circuit protection devices will not attempt to endorse either circuit breakers or fuses since each type of device has its own strengths and weaknesses. Instead, we will provide a clear understanding of both types of SCPDs and let the application requirements determine which protective device will best meet customer needs.

FUSES
Fuses are over-current protective devices that are placed in an electrical circuit to protect the control components, wiring, insulation, and motor from damage caused by excessive current and associated heat. Overcurrents are considered any increase in continuous current above the normal operating current level. In motor circuits, overcurrents are classified in two different categories. Motor overloads are any overcurrents up to or slightly above locked rotor current (6-8 times FLA). This range of overcurrent is protected by overload relay protection devices which will be discussed in more detail later. Short-circuit overcurrents are those produced by short-circuit or ground fault conditions with fault current levels in excess of 8 times FLA. In todays industrial facilities, short-circuit overcurrents can easily reach 50,000A. If the short-circuit overcurrents are not interrupted within fractions of a second, severe damage to the electrical installation can occur including motor damage, conductor and controller damage or even fires. In motor circuits, fuses best provide protection from damage caused by shortcircuit currents. Throughout the world, many different types of fuses are used for short-circuit protection in motor circuits. In North America, UL and CSA fuses are most commonly used. In other parts of the world, DIN (German) and BS88 (British) fuses are dominant. Even though the construction and fastening means are quite different (See Figure 2), all these fuses still perform the same essential function of short-circuit protection.

COORDINATED MOTOR CIRCUIT PROTECTION

Figure 2 The World of Fuses

BS88 Fuses IEC fuse type: Fuse-link for bolted connection Voltage rating: 660V AC Interrupting rating: 80,000A Standard cartridge sizes: A1, A2, A3, A4, B1, B2,
B3, and B4 Typical ampere ratings: 2400A Construction: Blade type for bolted connection Where commonly used: United Kingdom, Australia, New Zealand, Asia, and Middle East

DIN Fuses IEC fuse type: Fuse-link with blade contacts Voltage rating: 660V AC Interrupting rating: 100,000A Standard cartridge sizes: 00, 0, 1, and 2 Typical ampere ratings: 2400A Construction: Blade type Where commonly used: Europe, South America,
Middle East, and India

UL/CSA Fuses Operation: Time-delay; Current-limiting UL fuse type: Class CC CSA fuse type: HRCI-MISC Voltage rating: 600V AC Interrupting rating: 200,000A Standard cartridge sizes: 30A Typical ampere ratings: 130A Construction: Ferrule type Where commonly used: North America

COORDINATED MOTOR CIRCUIT PROTECTION

UL/CSA Fuses (cont.) Operation: Time-delay; Current-limiting UL fuse type: Class J CSA fuse type: HRCI-J Voltage rating: 600V AC Interrupting rating: 200,000A Standard cartridge sizes: 30A, 60A, 100A, 200A,
400A and 600A Typical ampere ratings: 1600A Construction: 160A; Ferrule type 61600A; Blade type for bolted connection Where commonly used: North America

Operation: Dual-element, Time-delay,

Current-limiting UL fuse type: Class RK1, RK5 CSA fuse type: HCR-R Voltage rating: 250 and 600V AC Interrupting rating: 200,000A Standard cartridge sizes: 30A, 60A, 100A, 200A, 400A and 600A Typical ampere ratings: 1/10600A Construction: 160A Ferrule Rejection type; 61600A; Blade type for wedge clamp connection Where commonly used: North America

Operation: Fast-acting; Current-limiting UL fuse type: Class T CSA fuse type: HCR-T Voltage rating: 300 and 600V AC Interrupting rating: 200,000A Standard cartridge sizes: 30A, 60A, 100A, 200A, 400A, 600A, 800A, 1200A Typical ampere ratings: 11200A Construction: 160A; Ferrule type; 611200A; Blade type for bolted connection Where commonly used: North America

COORDINATED MOTOR CIRCUIT PROTECTION

CSA Fuses CSA fuse type: HRCII-C Voltage rating: 600V AC Interrupting rating: 200,000A Standard cartridge sizes: 30A, 60A, 100A,
200A, and 400A

Typical ampere ratings: 1400A Construction: Blade type for bolted connection Where commonly used: Canada
Fuses are designed to meet specific standard performance requirements. In the case of UL and CSA fuses, specific characteristics such as current ratings, voltage rating, fuse dimensions, rejection features, withstand ratings, maximum I2T and Ip current let-through limits, trip time parameters (time-delay) and more are specified in the standards. Table A compares the performance requirements of various UL and CSA fuse classes. As you can see, different class fuses with similar current ratings can have significantly different results on I2T and Ip let-through values.
Table A Fuse Performance Requirements
UL Fuse Performance Requirements per UL 198, 600 Volts, 100kA Ampere Rating (A) UL Fuse Class K5, RK5 K1, RK1 J T CC K5, RK5 K1, RK1 J T Max I2t  103 (A2-Sec.) 50 10 7.0 7.0 7.0 200 40 30 30 Max. Ip  103 (A) 11 10 7.5 7.5 7.5 21 12 10 10

30

60

CSA Fuse Performance Requirements per CSA C22.2 No. 106 Ampere Rating (A) CSA Fuse Class HRCII-C HRCI-R HRCI-J HRCI-T HRCII-C HRCI-R HRCI-J HRCI-T Max I2t  103 (A2-Sec.) 50 50 7 7 200 200 30 30 Max. Ip  103 (A) 14 14 12 12 26 26 16 16

30

60

Fuses are tested on circuits with available fault currents between the threshold current of the fuse and 100,000 RMS symmetrical amperes.

COORDINATED MOTOR CIRCUIT PROTECTION

FUSE MECHANICS
Figure 3 illustrates the typical operation of a dual element-time delay fuse. As its name indicates, dual element means that the fuse incorporates two separate current sensing elements arranged in a series configuration (A). The overload element opens when continuous overcurrent conditions exist (B). During an instantaneous short-circuit condition, the short-circuit element will open in multiple locations (C), interrupting the short-circuit an limiting the let-through I2T and Ip within the limits specified by the fuse standard requirements.
Figure 3 Dual Element Time Delay Fuse
Shortcircuit Element

Alloy Solder Connection Overload Element (A) Construction

(B) Opening on Overload Condition

(C) Opening on Shortcircuit Condition

Several key benefits of using fuses for short-circuit protection includes: Low initial cost Current limiting High interrupting ratings Newer small dimension fuses (Class J & CC) Reliable operation

COORDINATED MOTOR CIRCUIT PROTECTION

CIRCUIT BREAKERS
An increasingly popular method of providing short-circuit protection in motor circuits is with the use of circuit breakers. Circuit breakers have become very popular due to the fact that following a fault condition, circuit breakers can be easily reset once proper troubleshooting and maintenance procedures are completed. The ability to reset a circuit breaker following a fault condition, allows the manufacturing process to begin operation with minimal downtime. There are many different types of circuit breakers on the market. In discussing the world of circuit breakers, we will concentrate on two groups of products. The first group will be UL/NEMA type molded case circuit breakers which are very popular in North America, and IEC type circuit breakers (motor circuit protectors) that are commonly used as short-circuit protection devices outside North America.

North American Circuit Breakers

The most commonly used circuit breakers in North America are referred to as molded case circuit breakers (MCCBs). These circuit breakers meet UL 489, CSA C22.2 No.5 and NEMA AB-1 standards requirements. These standards define circuit breaker characteristics such as ratings, performance, corrosion protection, electrical spacings, testing requirements, pass/fail criteria, insulating materials, current carrying parts, terminal wire capacities, etc. There are many different types of molded case circuit breakers including thermal-magnetic, magnetic-only, current-limiting, fused circuit breakers, and many more. This discussion will concentrate on thermal-magnetic and magnetic-only devices since they are the most popular type used in industry today.

Thermalmagnetic Circuit Breakers

Thermal-magnetic (inverse time) circuit breakers provide both thermal (overcurrent) and magnetic (short-circuit) protection within a single device. For thermal overcurrent protection, thermal elements (bimetallic or electronic) are used to protect the circuit components from damage caused by continuous levels of high overcurrent. As current passes through the thermal elements, they will deflect until a trip point is reached, at which time the circuit breaker will trip, opening the motor circuit. The thermal action is also associated with the characteristic of inverse time since low overcurrents require longer trip times and high overcurrents result in shorter trip times. For short-circuit protection, thermal-magnetic circuit breakers incorporate a magnetic trip element. During a short-circuit condition, the high fault current causes the magnetic trip element to release a latching mechanism, tripping the circuit breaker and opening the motor circuit.

COORDINATED MOTOR CIRCUIT PROTECTION

International Circuit Breakers

Although North American type circuit breakers are used around the world, motor circuit protectors that meet IEC 947 requirements are most common outside North America. The IEC type circuit protector incorporates several functions within a single device including On-Off push buttons for local control and motor circuit isolation, adjustable bimetallic elements for overload protection, and magnetic trip elements for short-circuit protection. Since the IEC type circuit protectors do not meet the UL 489 molded case circuit breaker requirements, they cannot be used as a stand-alone short-circuit protection device as UL molded case circuit breakers or fuses in the U.S. or Canada.
Figure 5 IEC Type Circuit Breakers

In the North American markets, the IEC motor circuit protectors have achieved what is called group motor rating. This UL/CSA rating allows several motor circuits, each using an IEC motor circuit protector, to be protected with a single UL/CSA short-circuit protective device (Figure 6). The elimination of individual motor circuit fuses or circuit breakers means significant panel size reduction. NEC Article 430-53 outlines the requirements for such installations.

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COORDINATED MOTOR CIRCUIT PROTECTION

Figure 6 North American Group Motor Installation

Disconnect Switch OR

Circuit Breaker

Fuses

Bul. 140

Bul. 140

Bul. 140

Bul. 140

Bulletin 140 Manual Starter and Protector Contactor for Remote Operation

M1

M2

M3

M4

In international markets, the IEC motor circuit protectors are recognized and utilized as stand-alone short-circuit protection devices. Not until the available fault current exceeds the interrupting capability of the the motor circuit protector, do back-up short-circuit protection devices need to be used (Figure 7).
Figure 7 Motor Installations Outside North America
Disconnect Switch

Bul. 140

Bul. 140

Bul. 140

Bul. 140

Bulletin 140 Manual Starter and Protector Contactor for Remote Operation

M1

M2

M3

M4

Several key benefits of using IEC circuit breakers include: Provide useful group motor ratings for North American applications Resetable after fault occurs Visible trip indication Overload protection Provide local On-Off and isolation
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COORDINATED MOTOR CIRCUIT PROTECTION

TYPE 2 COORDINATION
Type 2 Coordination is a term used to describe a level of protection that can be achieved by properly coordinating the selection of the short-circuit protection device with the withstand capability of the motor controller and overload protection device in the circuit. The concept of Type 2 Coordination originated from the IEC (International Electrotechnical Commission) standard 947-4-1. In this standard, two levels of short-circuit coordination are identified. Type 1 Coordination is defined as follows: Under short-circuit conditions, the contactor or starter shall cause no danger to persons or installation and may not be suitable for further service without repair and replacement of parts. In other words, contact welding is allowed in the contactor and overload burnout is acceptable. In either case, replacement of the control components are required. Type 2 Coordination on the other hand, limits the effect of a short-circuit on the control components. Type 2 Coordination is defined as follows: Under short-circuit conditions, the contactor or starter shall cause no danger to persons or installation and shall be suitable for further use. The risk of contact welding is recognized, in which case the manufacturer shall indicate the measures to be taken in regard to the maintenance of the equipment. Figure 8 illustrates the results of a short-circuit if a motor branch circuit was protected by current limiting device vs. a circuit without a current limiting device. In circuits using a current limiting device, the let-through energy is limited to less than 1/2 cycle. This limited level of let-through energy allows the control components to survive a short-circuit and continue operation with little or no maintenance required. In general, fuses have had much better current limiting capabilities than do circuit breakers, although some current limiting circuit breakers can provide Type 2 Coordination results. It is best to consult the control manufacturer for recommended short-circuit protection devices required to achieve Type 2 Coordination. Control manufacturers can provide component selection data (see Table B) that has already been proven during Type 2 testing programs. By following the manufacturers guidelines, you can be assured of achieving Type 2 Coordination in your motor branch circuit installation. Benefits of Type 2 coordination include: Increased productivity and less down time

Reduced component replacement costs Simple selection of SCPDs and motor circuit components with
manufacturer supplied data

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COORDINATED MOTOR CIRCUIT PROTECTION

Figure 8 Let-through Heat and Current

Current Peak available current (lp) without current limiting fuse NOT CURRENT-LIMITED

Normal Load Current

Heat Energy Time

Point of Fault

Current Peak available current (lp) without current limiting fuse CURRENT-LIMITED

Normal Load Current

Heat Energy Time

Point of Fault Fuse limits current less than 1/2 cycle At the inception of a fault, a branch circuit can reach peak available current (lp) without a current-limiting protector. The heat produced reaches temperatures that melt conductors as well as insulation, and the magnetic forces bend conductors and supports. When protected with a current-limiting fuse, however, the let-through current is only a fraction of lp, usually opening the fuse in less than one-half cycle. Type 2 Coordination assures that no harm to people or damage to equipment results from short-circuit currents.

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COORDINATED MOTOR CIRCUIT PROTECTION

Table B Manufacturer Fuse Recommendation for Type 2 Coordination

Motor Horsepower Single Phase 115V 1/10 1/8 1/6 1/4 1/3 1/2 3/4 1 1-1/2 2 230V 1/10 1/8 1/6 1/4 1/3 1/2 3/4 1 1-1/2 2 3 200V 1/2 3/4 1 1-1/2 2 3 5 Three-phase 230V 1/2 3/4 1 1-1/2 2 3 5 7-1/2 460V 1/2 3/4 1 1-1/2 2 3 5 7-1/2 10 15 575V 3/4 1 1-1/2 2 3 5 7-1/2 10 15 20 Basic Cat. No. 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A09 100-A12 100-A12 100-A12 100-A18 100-A18 100-A24 100-A24 Contactor Overload Relay Fuse Max. Amp. Rating 2 2 3 3 6 6 6 6 6 10 10 10 15 15 20 20 20 30 30 30 UL Listed Time-delay Class J (CSA HRCI-J) Fuse Cat. No. Bussman LPJ-2 LPJ-2 LPJ-3 LPJ-3 LPJ-6 LPJ-6 LPJ-6 LPJ-6 LPJ-6 LPJ-10 LPJ-10 LPJ-10 LPJ-15 LPJ-15 LPJ-20 LPJ-20 LPJ-20 LPJ-30 LPJ-30 LPJ-30 GouldShawmut AJT2 AJT2 AJT3 AJT3 AJT6 AJT6 AJT6 AJT6 AJT6 AJT10 AJT10 AJT10 AJT15 AJT15 AJT20 AJT20 AJT20 AJT30 AJT30 AJT30 Littlefuse JTD2 JTD2 JTD3 JTD3 JTD6 JTD6 JTD6 JTD6 JTD6 JTD10 JTD10 JTD10 JTD15 JTD15 JTD20 JTD20 JTD20 JTD30 JTD30 JTD30

Cat. No. 193-BSB16 193-BSB16 193-BSB22 193-BSB22 193-BSB30 193-BSB30 193-BSB42 193-BSB42 193-BSB50 193-BSB60 193-BSB80 193-BSB80 193-BSC10 193-BSC10 193-BSC15 193-BSC15 193-BSC15 193-BSC24 193-BSC24 193-BSC24

By following manufacturer recommendation for maximum short-circuit protection device allowed, automatic Type 2 Coordination can be achieved.

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COORDINATED MOTOR CIRCUIT PROTECTION

MOTOR OVERLOAD PROTECTION

Overload relays are used in a motor circuit to protect motors and circuit conductors from damage caused by prolonged periods of overcurrent conditions. If motors are exposed to increased levels of continuous current and prolonged periods at locked rotor condition, damage to the motor and circuit conductors can occur. Motors can be damaged or destroyed under any of the following conditions. Low or high supply voltage Phase unbalance Continuous excessive loading Single-phasing Jam or stall conditions Ground/earth faults Mechanical failures such as seized motor bearing or binding mechanical linkages By selecting the proper type of overload relay with the appropriate functionality, the motor can be protected from damage caused by these conditions.

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COORDINATED MOTOR CIRCUIT PROTECTION

TYPES OF OVERLOAD RELAYS

Today three basic types of overload relays are available: eutectic alloy, bimetal, and solid-state. Lets take a closer look at each type of overload relay and review the basic features of each.

Eutectic Alloy Overload Relays

Eutectic alloy overload relays are typically used with NEMA motor starters. These overload relays utilize a solder type alloy within heater elements. As current moves through the heater element, the solder is heated until a predetermined melting point (trip point) is reached. At the trip point, the solder is instantaneously changed from a solid to a liquid, allowing the ratchet mechanism to open a normally closed contact, dropping out the starter coil circuit, Figure 9.
Figure 9 NEMA Type Eutectic Alloy Overload Relay
Eutectic Alloy Heater L1 Ratchet Pawl T1

To Starter Coil

Key features of a eutectic alloy overload relay: Tamper-proof Not effected by nuisance tripping caused by vibration Manual reset only Single-phase sensitive Selectable trip classes 10, 20, 30

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COORDINATED MOTOR CIRCUIT PROTECTION

Bimetal Overload Relays

Two types of bimetal overload relays are available, NEMA and IEC. The NEMA type bimetal overload relay utilizes replaceable heater elements that indirectly heat bimetal strips. As the bimetal strips are heated, they flex towards a trip point, at which time a normally closed contact will open, dropping out the starter coil, Figure 10.
Figure 10 NEMA Type Bimetal Overload Relay
Trip Bar Heater Element Contacts

Power Circuit

Bimetal Strip

To Starter Coil

Key features of a NEMA type bimetal overload relay: Flexibility of changeable heater elements. Automatic reset Selectable trip classes 10, 20, 30 Ambient temperature compensation Single-phase sensitive

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COORDINATED MOTOR CIRCUIT PROTECTION

Bimetal Overload Relays, Continued

IEC bimetal overload relays are similar to the NEMA devices except that the heater/bimetal are integral to the overload relay, Figure 11. To allow for added flexibility, the overload trip setting is adjustable over a range of motor full load current settings. The typical FLA setting range would be 1.0:1.5 (min. to max. setting). IEC bimetal overload relays are typically designed to Class 10 trip characteristics. This means that the overload relay will trip in less than 10 seconds at locked rotor current.
Figure 11 IEC Type Bimetal Overload Relay
L1 L2 L3 Heater Bimetal Strip Trip Bar To Starter Coil

Key features of an IEC type bimetal overload relay are: Manual or automatic reset Ambient temperature compensated Single-phase sensitive Wide current adjustment range (1:1.5)

Solid-state Overload Relays

Solid-state (electronic) overload relays are the newest and fastest growing type of overload protection devices. Until recently, solid-state overload relays were large, costly, and impractical for use on the vast majority of small motors used in industry today. With recent development in solid-state overload technology, the cost and size of the solid-state devices have been significantly reduced while the functionality has been greatly increased. The latest solid-state overload relay technology utilizes integral current transformers, application specific integrated circuits (ASIC), and/or microprocessors along with electromechanical design principles to produce a compact, high functionality overload protection solution. Available in either NEMA or IEC versions, the principle of operation is the same. As motor current passes through the integral current transformers, power is available to supply the integrated circuit. By monitoring the three-phase power, the ASIC can process current data, and activate a trip mechanism on overload conditions, opening a normally closed contact and dropping out the motor starter coil circuit, Figure 12.

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COORDINATED MOTOR CIRCUIT PROTECTION

ADVANCED MOTOR PROTECTION

As a result of integrating a microprocessor or an application specific integrated circuit (ASIC) as the brains of a solid-state overload relay, the opportunity to add advanced protective functionality to the overload relay becomes very practical.
Figure 14 Advanced Overload Protection Devices

Besides basic overload protection, advanced solid-state overload relay devices can offer additional functionality that previously would have required several additional protection devices to be used in the motor circuit. By consolidating many protective features into a single device, installation costs, component costs, panel size, and maintenance time can be significantly reduced while performance and efficiency of the system can be increased. An additional benefit of solid-state devices is its ability to function via network communications. Through a communication network, vital motor information can be collected, processed and displayed in order to take corrective action prior to reaching fault conditions. Examples of data that can be obtained through the solid-state overload relay include: % Thermal capacity used (0100%) How close is the motor to a trip condition (100%)? Phase unbalance Average current FLA settings Fault frequency Fault cause indication Through triac outputs, control via a communication network can occur. Control functions include: Start/Stop Reset Restart limit
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COORDINATED MOTOR CIRCUIT PROTECTION

Table C Advanced Solid-state vs. Traditional OLRs

Advanced Protection Feature D Jam/Stall protection selectable I/O selectable D Ground (earth) fault protection selectable I/O selectable D Single-phase protection D Trip setting accuracy D Repeat accuracy of trip setting D LED trip indication Solid-state OLRs D Trips within .5 sec. at 400% of FLA setting D Monitors phase vector angles Trips at lower level prior to fault level D Trips within two sec. on fully loaded motor D Dip switch setting increased accuracy 2.5% D Increased accuracy 1% D Fault cause indication Jam/Stall Ground earth fault Improper setting Communication loss Test Phase loss Overload D Wide current adjustment range D Low power requirement and low heat dissipation D Trip classes 10, 15, 20, 30 D Network communications D 3.2:1 and 5:1 D 150mW per device D Selectable by DIP switch setting D Control, data acquisition and fault cause indication D Control Start/stop Reset Restart limit D Data acquisition % thermal capacity used (trip warning) Trip frequency Phase unbalance FLA trip setting Average current D Fault cause indication (see above) D 1.6:1 and 1.1:1 D 6W or greater per device D Dedicated components per trip class D None Traditional OLRs D Relays on overload trip curve response D None rely on SCPD

D Sensitive to singlephase conditions Trips in 40 sec. or longer D Potentiometer or heater elements: 10% D 510% D None

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COORDINATED MOTOR CIRCUIT PROTECTION

COORDINATED MOTOR CIRCUIT PROTECTION

Coordinated motor circuit protection for a branch circuit consists of providing a continuous level of damage protection from minor overloads through major short-circuit currents. Such protection provides benefits of reduced down time and replacement costs as well as greater safety. The purpose of the overload protection in any branch circuit is to provide starting and running protection from overcurrents caused by such problems as binding bearings or jammed parts in the machine. These overcurrents range up to motor locked rotor current, usually about six times the motor full load current. Since locked rotor current is also initial starting current, overload protective devices require some designed in time delay in order to prevent nuisance tripping during start up. The time/current curve of an overload protective device shows that the time to trip is inversely related to the magnitude of overload current.
Figure 15 Overload Response Curve

Time in Seconds

10

Multiples of FLC

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COORDINATED MOTOR CIRCUIT PROTECTION

The purpose of the short-circuit protective device is to prevent higher levels of overcurrent from damaging components of the motor branch circuit. Short-circuit currents are considered to range from motor locked rotor current up to the maximum current available at the motor circuit Short-circuit currents result from such problems as wiring errors, insulation breakdown, and accidental contact with the circuit by tools or other metal objects. Short-circuit protective devices must react quickly to minimize damage. The time/current curve for a short-circuit protective device shows its trip timIt is also inversely related to current. You can see, however, that the slope of the curve is very steep.
Figure 16 Short-circuit Protective Device Responsive Curve

Time in Seconds

10

Multiples of FLC

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COORDINATED MOTOR CIRCUIT PROTECTION

The National Electrical Code requires short-circuit and overload protection for the branch circuit. If these curves are overlaid we then have a time current curve that illustrates the behavior of the protective devices for all levels of current. If the curves intersect, the point of intersection is called coordination point. This point should be just above motor locked motor current (68  FLC) for proper coordination. If the curves are properly coordinated, the short-circuit protective device will react to currents above the overload range, but will not trip if the overcurrent is in the overload range.
Figure 17 Coordinated Motor Circuit Protection
Short-circuit Protective Devices

Overload Relay COORDINATION POINT

Time in Seconds

Motor Running Overprotection Protection

Motor Branch Circuit Short-circuit Protection

10

Multiples of FLC

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COORDINATED MOTOR CIRCUIT PROTECTION

If, however, these curves do not intersect, or intersect well above the motor locked rotor current, the overload protective device will react to short-circuit currents in the gap between the overload range and short-circuit protection, and probably be damaged.
Figure 18 Protection Not Coordinated (Curves Do Not Intersect)

Overload Relay

Short-circuit Protective Devices

Time in Seconds

10

Multiples of FLC

If the curves intersect in the overload range below the locked rotor current, the short-circuit protective device will nuisance trip on motor start-up.
Figure 19 Protection Not Coordinated (Curves intersect at less than locked rotor current)

Time in Seconds

Overload Relay

Short-circuit Protective Devices

10 25

Multiples of FLC

COORDINATED MOTOR CIRCUIT PROTECTION

LIFE OF A TYPICAL MOTOR INSTALLATION

Over the life of a typical motor installation, several different fault conditions can occur, from high level faults such as short-circuits or ground faults to low level faults such as overloads and jam conditions. When selecting motor circuit protection devices, several questions should be raised. Is the motor circuit critical to the manufacturing process? What is the total cost of downtime in the application? Is the application more susceptible to certain types of fault conditions? Is Type 2 Coordination important? Do I need to collect motor data and be warned of impending fault? Are fuses or circuit breakers preferred for short-circuit protection? Dependent on the answers to these questions (and possibly many others), the process can begin to specify the type of products required to adequately protect the motor circuit. For less critical applications such as a fan or blower, where critical manufacturing processes or safety issues are not a consideration, meeting code requirements with fuses and a traditional overload relay may be the ideal solution. On the other hand, in a critical application, where the manufacturing process relies on a continuous flow of materials and downtime can be very costly, the best protection solution may require the following capabilities: Selecting a short-circuit protection device that provides Type 2 Coordination Selecting a solid-state overload device that provides: Ground fault protection Jam/Stall protection Network communications to more closely monitor the motor data and application By properly outlining the application requirements and selecting the appropriate protection components, the optimum implementation costs and motor circuit protection scheme can be developed to optimize the maximum life and performance of the motor and application.

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COORDINATED MOTOR CIRCUIT PROTECTION

Figure 20 Life of a 40 HP Motor

Crusher Application 40 HP Motor (50A FLC)

Ie 100,000 50,000 10,000 5,000 1,000 500 100 Motor FLA 50 0 Fault Type ShortCircuit Ground/ Earth Overload Phase Loss Jam/Stall Impending Trip WARNING! 100% 2 Sec. 40 Sec. 1/2 Sec. 15 Sec. Time

Fuses or Circuit Breakers

Protection Device Type Trip Due to Low Level Ground Fault High Level Faults

Traditional Overload Protection Devices

Responds with Overload Trip Curve Advanced Protection via Network Communications D % Thermal Capacity used D Phase Unbalance D Start-Stop-Reset Control D Restart Limit

Solid-state Overload Protection Devices

Low Level Faults

Coordinated Motor Circuit Protection Point

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COORDINATED MOTOR CIRCUIT PROTECTION

TERMINOLOGY
To help understand Coordinated Motor Circuit Protection, it is necessary to be familiar with the characteristics and definitions related to fuses, circuit breakers, overload relays, short-circuit, and overload protection. Ampere Rating The continuous current carrying capability of a fuse or circuit breaker. Ampere-squared Seconds (I 2t) An expression related to the thermal energy associated with current flow. Available Fault Current The maximum possible short-circuit current that can flow in an unprotected circuit. BS88 Fuse Designations British Standards Institute has defined basic physical specifications (size, mounting dimensions, labeling) and guidelines to fuse manufacturers for providing maximum let-through current and energy for fuses (in a standard format). Fuse designed to British Standards are described by their dimension (e.g., Al, A2, A3, A4, B1, etc.) and continuous current rating. Circuit Breaker A device designed to open and close a circuit by non-automatic means and to open the circuit automatically on a predetermined overload current. Clearing Time The total time measured from the beginning of the fault to the interruption of the circuit. Current Limiting Circuit Breaker A circuit breaker that does not employ a fusible element and that when operating within its current limiting range, limits the let-through I2t to a value less than the I2t of a 1/2 cycle wave of the symmetrical prospective current. Current Limiting Fuse A fuse which will limit both the magnitude and duration of current flow under short-circuit conditions. The available fault currents a fuse will clear in less than 1/2 cycle, thus limiting the actual magnitude of current flow. DIN Fuse Designations DIN/VDE Standards specify physical specifications as well as classes of operation for fuses. The class of operation is identified by two or three letters (e.g., gL, aM, gTr). The gL fuse is a general purpose fuse with characteristics that are well suited for the protection of starters and associated wiring. These fuses are described by their dimension (e.g., 00, 0, 1, 2, 3 and 4) and continuous current rating.

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COORDINATED MOTOR CIRCUIT PROTECTION

Dual-element Time Delay Fuse A fuse of special design which

utilizes two individual elements in series inside the the fuse casing. One element is a spring-actuated trigger assembly that operates that operates on sustained overloads, but which ignores momentary surges. The other element operates without intentional delay on currents of fault magnitude up to the interrupting rating of the fuse. Fast-acting Fuse A fuse that opens very quickly on currents of fault magnitude. This type of fuse is designed with no intentional time-delay characteristics. Fast-acting fuses are commonly used to protect solid-state electronic devices. Fuse An overcurrent protective device with a fusible link that operates to open the circuit on an overcurrent condition. High Level Fault Short-circuit currents between the threshold current of a fuse that would be used for the branch circuit protection of a motor in a given application and the test current for the controller of that motor, per the short-circuit test of UL 508. Interrupting Rating The maximum short-circuit current that an overcurrent protective device can safely open or clear. Let-through Energy (I 2t) A measure of thermal energy developed within a circuit during the total clearing time of the fault current. Low Level Fault Short-circuit currents that are less than the threshold current of a fuse that would be used for the branch circuit protection of a motor in a given application. Overcurrent A condition existing in an electrical circuit when normal current is exceeded. Overcurrents occur in two distinctly separate forms overloads and short-circuits. Overload An overcurrent that exceeds the normal full-load current of a circuit. Overload Current A level of current above the motor full load current, but generally not greater than six times the full load current. Overload currents are usually caused by overloading the motor and are restricted to the normal current path. These currents are typically detected by the overload relay. Peak Let-through Current (Ip) The maximum instantaneous peak current passed through a short-circuit protective device when clearing a fault current of specified magnitude. RMS Current The effective, root-mean square value of current, and the measure of its heating effect. The RMS value is calculated as the square root of the mean of the squares of all the instantaneous values of the current throughout one cycle. RMS alternating current is the value of an alternating current that produces the same heating effect as a given value of direct current. Short-circuit Current Excessive current caused by insulation breakdown or wiring error. Short-circuit currents leave the normal current carrying path of the circuit, such as line-to-line or line-to-ground. Short-circuits are typically detected and cleared by the branch circuit protective devices.

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COORDINATED MOTOR CIRCUIT PROTECTION

Single-phasing The condition that exists when one phase of a

three-phase power system opens. Single-phasing results in unbalanced currents and overheating in polyphase motors and other three-phase inductive devices. Proper selection of dual-element time-delay fuses and/or protective relays will help protect motors from damage during single-phasing conditions. Threshold Current The magnitude of current a which an SCPD becomes current limiting. Time-delay Fuse A fuse with a built-in time delay that allows temporary a harmless inrush currents to pass without opening, but is designed to open on sustained overloads and currents short-circuit magnitude. UL Class of Fuse/CSA Fuse Designations Underwriters Laboratories and the Canadian Standard Association have developed basic physical specifications (size, rejection features, labeling) and electrical performance requirements (interrupting rating, maximum Ip and I2t) for fuses with voltage ratings of 600 volts or less. If a fuse meets these requirements, it can be designated by a UL class of fuse or a CSA fuse designation. Typical UL fuse classes are K1, K5, RK1, RK5, J, T, and CC. Typical CSA fuse designations are HRCI-T HRCI-R, HRCI-J, and HRCII-C. Voltage Rating The maximum value of system voltage in which a fuse can be used and safely interrupt an overcurrent. Exceeding the fuse voltage rating impairs its ability to clear an overload or short-circuit safely.

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AllenBradley is committed to supporting you throughout each phase of the Automation Investment Life Cycle.
AllenBradley offers a wide range of motor protection products that will help extend the life of your motor. These products are an integral part of the automation process and the life cycle. Justify. If your application requires motor protection, choose any one of our solutions for increased productivity. These product lines offers many protective features such as detection of overload, short circuit and ground fault conditions. Analyze the complete line of motor protection products through customer training seminars, product demonstrations and literature. Apply. Any one of the motor protection devices may be applied based upon your application and requirements. Many of these products work together to provide increased functionality. Install. Integrate our products with new systems as well as existing systems. Traditional and solidstate protection is available. Our panel system solution reduces wiring and installation costs. Operate. Striving for optimum productivity and monitoring motor faults constitute proactive approaches to this phase. Maintain. By protecting the motor from damage, our products help reduce downtime. Product features such as diagnostics and communications capability also reduce system maintenance. Improve. Extending the life of your motor is the main benefit of our product line. As your needs change, we change with you by increasing the effectiveness of our products and monitoring market demands. Staying focused on product line improvements results in advanced product offerings such as the SMPTM Overload Relays and the Smart Motor Manager.
The Automation Investment Life Cycle graphic and SMP are trademarks of the AllenBradley Company.

Publication 1932.10 July 1995

Copyright 1995 Allen-Bradley Company, Inc., a Rockwell International company Printed in USA

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